Method and apparatus for reconditioning digital discs

ABSTRACT

An automated method for reconditioning a plurality of digital discs within a reconditioning apparatus is disclosed. The method comprises holding the digital discs in a load area, and then transferring each of the digital discs from the load area to at least one workstation with a disc transfer mechanism. The method also comprises reconditioning each of the digital discs transferred to the workstation with at least one worktool operable to remove a portion of the protective coating of each of the digital discs without removal of the data underlying the protective coating. The method further comprises transferring each of the digital discs from the workstation to an unload area with the disc transfer mechanism, and then holding the digital discs in the unload area for manual retrieval. Advantageously, the digital discs may be automatically reconditioned within the reconditioning apparatus without manual manipulation of the digital discs during the reconditioning process. Various exemplary embodiments of the reconditioning apparatus and associated method are provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/312,894, filed on Dec. 19, 2005, which is a continuation-in-part ofU.S. patent application Ser. No. 09/611,625, filed on Jul. 7, 2000,entitled “Method and Apparatus for Reconditioning Digital Discs,” bothof which are incorporated herein, in their entireties, by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method and apparatus forreconditioning digital discs and, more particularly, to an automatedmethod and apparatus that allows digital discs to be reconditionedwithout manual manipulation of the digital discs during thereconditioning process.

2. Description of Related Art

Digital discs are used to store many different types of information,such as computer data, video games, music, movies and the like. Two ofthe more common types of digital discs are compact discs (CDs) anddigital video discs (DVDs). Typically, a digital disc comprises a layerof aluminum on which is deposited digital data to be read by a computer,video game system, CD player, DVD player and the like. A plasticprotective coating overlays the digital data so as to provide protectionfor the data on the digital disc.

The protective coating of a digital disc may become scratched orotherwise damaged during use of the disc. This occurs more frequently insituations where the digital disc is not owned by the user, such as inrental operations where a customer has no particular reason to take careof the digital disc during rental. As a result, the digital disc may bereturned to the rental establishment in a damaged condition. Because thedigital data underlying the protective coating typically retains itsintegrity, it is possible to restore the protective coating to itsoriginal condition or, at least, to a condition where the digital datacan be properly read through the protective coating. By so doing, theneed for discarding the damaged digital disc is obviated and, thus, itis not necessary to incur the expense of purchasing an additional copyof the digital disc.

Various apparatuses for reconditioning the protective coating of adigital disc are known in the art (see, for example, U.S. Pat. No.5,954,566 to Bauer, U.S. Pat. No. 5,733,179 to Bauer, and U.S. Pat. No.6,322,430 to Kennedy). However, in each of these apparatuses, thedigital disc must be manually manipulated during the reconditioningprocess. Thus, in order to recondition a large number of digital discs,the operator must manually place each of the digital discs into theapparatus, wait for the reconditioning process to be completed, and thenmanually remove each of the digital discs from the apparatus. In some ofthese apparatuses, the operator must also manipulate each of the digitaldiscs during the reconditioning process itself. It can be appreciatedthat the time and manpower needed to recondition a large number ofdigital discs in these apparatuses can be prohibitive. As such, theseapparatuses are best-suited for reconditioning a single digital disc ora small number of digital discs.

SUMMARY OF THE INVENTION

The present invention is directed to an automated method forreconditioning a plurality of digital discs within a reconditioningapparatus. In accordance with the invention, a plurality of digitaldiscs are placed in a load area, whereby a disc transfer mechanismsuccessively transfers each of the digital discs from the load area toone or more workstations. Each workstation includes a turntable forsupporting a digital disc, and at least one worktool operable to removea portion of the protective coating of the digital disc without removalof the digital data underlying the protective coating. The disc transfermechanism then successively transfers each of the digital discs from theone or more workstations to an unload area for manual retrieval.

In a first exemplary embodiment, the reconditioning apparatus comprisesa load area that includes a load cartridge configured to hold aplurality of digital discs to be reconditioned. The load area alsoincludes a turntable that is rotatable between a load position (whereineach of the digital discs is successively deposited from the loadcartridge onto the turntable) and an unload position (wherein each ofthe digital discs is successively removed from the turntable fortransfer to the workstations).

In this embodiment, four workstations are used for reconditioning eachof the digital discs. The first and second workstations each include arotatable turntable for supporting a digital disc, and rotatableworktools operable to sand the protective coating of the digital disc.The third workstation includes a rotatable turntable for supporting adigital disc, and worktools operable to rinse and wax the protectivecoating of the digital disc. The fourth workstation includes a rotatableturntable for supporting a digital disc, and rotatable worktoolsoperable to polish the protective coating of the digital disc.

The disc transfer mechanism of this embodiment comprises multiplesuction tools operable to transfer each of the digital discs from theturntable of the load area (in its unload position) to the turntables ofeach of the four workstations and to an unload area. The unload areaincludes an unload cartridge configured to hold all of the digital discsafter reconditioning for manual retrieval by the operator. A controlleris used to properly sequence the various events occurring during thereconditioning process.

In a second exemplary embodiment, the reconditioning apparatus comprisesa load area that includes a load stack configured to hold a plurality ofdigital discs to be reconditioned. In this embodiment, a singleworkstation is used for reconditioning each of the digital discs. Theworkstation includes a disc tray with a rotatable turntable forsupporting a digital disc. The disc tray is moveable between an extendedposition (wherein a digital disc may be deposited onto the turntable)and a retracted position (wherein a digital disc may be reconditionedwithin the apparatus). The workstation also includes worktools operableto remove a portion of the protective coating of a digital disc withoutremoval of the data underlying the protective coating.

The disc transfer mechanism of this embodiment comprises a rotatablepick-up mechanism having a first arm positioned substantiallyperpendicular to a second arm. The first arm is operable to grasp adigital disc from the load stack and deposit the digital disc on theturntable of the workstation (when in its extended position). The secondarm is operable to grasp a digital disc from the turntable of theworkstation (when in its extended position) and deposit the digital discat an unload area. The unload area includes an unload stack configuredto hold all of the digital discs after reconditioning for manualretrieval by the operator. A controller is used to properly sequence thevarious events occurring during the reconditioning process.

The reconditioning apparatus of the present invention has severaladvantages over the prior art. For example, a large number of digitaldiscs may be automatically reconditioned within the reconditioningapparatus without manual manipulation of the digital discs during thereconditioning process. As a result, the time and manpower needed torecondition a large number of digital discs is greatly reduced. Ofcourse, other advantages of the present invention will be apparent toone skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in greater detail in thefollowing detailed description of the invention with reference to theaccompanying drawings that form a part hereof, in which:

FIG. 1 is a perspective view of a reconditioning apparatus in accordancewith a first exemplary embodiment of the present invention;

FIG. 2 is a side view of the reconditioning apparatus of FIG. 1, showingthe rotatable shaft and suction tools of the disc transfer mechanismused to advance a digital disc through the reconditioning apparatus;

FIG. 3 is a top view of the reconditioning apparatus of FIG. 1, showingthe rotatable turntable of the load area, the worktools and drive beltsof each of the workstations, and the rotatable shaft of the disctransfer mechanism;

FIG. 4 is a front view of the reconditioning apparatus of FIG. 1,showing the rotatable turntable and worktools of each of theworkstations;

FIG. 5 is a perspective view of a reconditioning apparatus in accordancewith a second exemplary embodiment of the present invention;

FIG. 6 is a partial perspective view of the reconditioning apparatus ofFIG. 5, showing the pick-up mechanism in the load position;

FIG. 7 is a partial perspective view of the reconditioning apparatus ofFIG. 5, showing the pick-up mechanism in a transitional position;

FIG. 8 is a partial perspective view of the reconditioning apparatus ofFIG. 5, showing the pick-up mechanism in the unload position;

FIG. 9 is a perspective view of the disc tray of the reconditioningapparatus of FIG. 5;

FIG. 10 is a perspective view of the turntable of the disc tray of FIG.9, and the associated drive motor and planetary gears;

FIG. 11 is a perspective view of the worktool housing and worktools ofthe reconditioning apparatus of FIG. 5;

FIG. 12 is an upwardly-looking perspective view of the worktool housingand worktools of FIG. 1, showing the associated abrasive pads andplanetary gears;

FIG. 13 is an elevational view of the worktool housing and worktools ofFIG. 11, showing the worktools in a lowered position so as to contactthe digital disc on the turntable; and

FIG. 14 is an elevational view of the worktool housing and worktools ofFIG. 11, showing the worktools in a raised position, not in contact withthe digital disc on the turntable.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to an automated method forreconditioning a plurality of digital discs within a reconditioningapparatus. A first exemplary embodiment of a reconditioning apparatusconstructed in accordance with the present invention is shown in FIGS.1-4, and a second exemplary embodiment of a reconditioning apparatusconstructed in accordance with the present invention is shown in FIGS.5-14. While the present invention will be described in detailhereinbelow with reference to these exemplary embodiments, it should beunderstood that the invention is not limited to the specificconstructions of the reconditioning apparatuses shown in theseembodiments. Rather, one skilled in the art will appreciate that a widevariety of reconditioning apparatuses may be constructed in accordancewith the present invention.

First Exemplary Embodiment

Referring to FIG. 1, a reconditioning apparatus constructed inaccordance with a first exemplary embodiment of the present invention isillustrated generally at 100. Apparatus 100 comprises four principaloperating areas, namely, a load area generally illustrated at 101, adisc reconditioning area generally illustrated at 102, a motive areagenerally illustrated at 103, and an unload area generally illustratedat 104. As will be described in detail hereinbelow, a controller 105 isused to properly sequence the various events occurring during thereconditioning process.

Load Area

Referring to FIGS. 1 and 3, load area 101 comprises a turntable 110 thatis rotatable by an electric motor 111, such as a DC type motor. Motor111 is adjustable to provide various revolution speeds as the operatormay desire for a particular operation. Turntable 110 is a plasticcomposite type turntable with a circular recess 112 (or multiplecircular recesses) formed therein. Recess 112 is approximately 3/16 inchdeep and has the approximate diameter of a digital disc to bereconditioned. Load area 101 further includes a load cartridge 113 thatis configured to hold a plurality of digital discs. In this embodiment,load cartridge 113 is configured to hold 60 to 100 digital discs. Eachof these digital discs enters recess 112, one by one, during the loadoperation.

Turntable 110 is rotatable about an axis of rotation 114 by use of anarm or bell crank 164 (shown in FIG. 3). Bell crank 164 is operated bymotor 111 and functions to rotate turntable 110 between a load positionand an unload position. In the load position, recess 112 is positioneddirectly beneath load cartridge 113, whereby a single digital disc isdeposited from load cartridge 113 into recess 112. In the unloadposition, the digital disc held by recess 112 is brought into positionfor removal by suction tools (described hereinbelow), whereby thedigital disc is advanced to various workstations for reconditioning. Ofcourse, the speed of motor 111 can be increased or decreased in order tochange the speed with which the digital discs enter disc reconditioningarea 102 (described hereinbelow).

Disc Reconditioning Area

Referring to FIGS. 1 and 4, disc reconditioning area 102 comprises aseries of four workstations each of which includes a rotatable turntable120, 121, 122, 123. An electric motor 133, such as a DC type motor, ismounted on a lower frame 134 and drives turntables 120, 121, 122, 123 atrotational speeds as desired by the operator for a particular operation.As best seen in FIG. 2, motor 133 drives turntables 120, 121, 122, 123by rotation of pulleys 179 (only one of which is shown) connected viabelts (not shown) to turntables 120, 121, 122, 123.

The first workstation defined by turntable 120 is a sanding workstation.This workstation includes three worktools 144, 145, 146. Worktools 144,145 are sanding tools that utilize an aluminum oxide or carbide materialfor contacting and sanding the protective coating of the digital disc onturntable 120. Worktools 144, 145 remove a small amount of material fromthe protective coating of the digital disc on turntable 120 to therebyperform the initial reconditioning operation. Worktool 146 is a holdingmember that exerts a downwardly directed force on the digital disc onturntable 120. Worktool 146 has a head that rotates with turntable 120.The function of worktool 146 is to exert sufficient force on the digitaldisc on turntable 120 so as to avoid any skipping or other dislocatedmovement of the digital disc during contact with worktools 144, 145.

The second workstation defined by turntable 121 is another sandingworkstation. This workstation includes three worktools 150, 151, 152.Worktools 150, 151 are sanding tools that utilize a borax powderedmaterial for contacting and sanding the protective coating of thedigital disc on turntable 121. Worktools 150, 151 finely remove anadditional amount of material from the protective coating of the digitaldisc on turntable 121 (which may be present following the materialremoval at the first workstation). Worktool 152 is identical to worktool146 described hereinabove and functions to maintain the digital disc onturntable 121.

The third workstation defined by turntable 122 is a rinse and waxworkstation. This workstation includes three worktools 153, 154, 155.Worktool 153 emits a rinsing solution to rinse off any material that hasbeen removed from the digital disc at the first and second workstations.Worktool 154 emits a waxing material to coat the upper surface of thedigital disc on turntable 122 and thereby provide a new protectivecoating. It should be understood that worktools 153, 154 are positionedin close proximity to, but do not contact, the digital disc on turntable122. Worktool 155 is identical to worktools 146, 152 describedhereinabove and functions to maintain the digital disc on turntable 122.

The fourth workstation defined by turntable 123 is a polishingworkstation. This workstation includes three worktools 160, 161, 162.Worktools 160, 161 are polishing tools that utilize a buffing materialmounted on their heads for contacting and polishing the protectivecoating of the digital disc on turntable 121. Worktool 162 is identicalto worktools 146, 152, 155 described hereinabove and functions tomaintain the digital disc on turntable 123.

In this embodiment, there are three independently operated motors usedto rotate worktools 144, 145 of the first workstation, worktools 150,151 of the second workstation, and worktools 160, 161 of the fourthworkstation. For example, worktools 144, 145 of the first workstationare rotated with the use of pulleys 180 (shown in FIG. 4) driven viabelts (not shown) by a DC motor 147. Worktools 150, 151 of the secondworkstation and worktools 160, 161 of the fourth workstation are rotatedin the same manner. The rotational speed of the worktools at eachworkstation may be adjusted relative to the rotational speed of theworktools at other workstations due to the different operations takingplace at each of the workstations. It should be noted that no rotationalmovement of worktools 153, 154 of the third workstation is necessarybecause these worktools are used to emit a rinse solution and a waxsolution, respectively.

Motive Area

Referring to FIG. 1, motive area 103 comprises a disc transfer mechanismthat includes a rotatable and reciprocal shaft 124 connected to aplurality of suction tools 130. Shaft 124 is hollow so that it may carrya vacuum or negative pressure that is transferred to suction tools 130.The suction within shaft 124 is generated by passing pressurized airthrough a nozzle and over a port (not illustrated) attached to shaft124. As best shown in FIG. 2, shaft 124 may be rotated about its axis bypneumatic cylinder 173, and, as shown in FIG. 4, may be reciprocatedalong its axis by pneumatic cylinder 174. Of course, hydraulic cylinderscould alternatively be used instead of pneumatic cylinders 173 and 174.

In this embodiment, five sets of suction tools 130 are connected toshaft 124. Each set of suction tools 130 is comprised of three rubbersuction heads 131 connected to a mounting frame 132. Mounting frame 132is made from tubing that allows the suction within shaft 124 to betransferred to suction heads 131. Each set of suction tools 130 is usedto simultaneously lift and move each of the digital discs from the loadarea to the first workstation, from the first workstation to the secondworkstation, from the second workstation to the third workstation, fromthe third workstation to the fourth workstation, and from the fourthworkstation to unload area 104 (described hereinbelow).

Unload Area

Referring again to FIG. 1, unload area 104 comprises a receivingcartridge 163 positioned after the fourth workstation at the end ofapparatus 100. Receiving cartridge 163 is configured to receive and holdeach of the digital discs after the reconditioning process has beencompleted. It should be understood that the digital discs may then bemanually retrieved from receiving cartridge 163 by the operator.

Operation

With reference to FIGS. 1-4, the operation of reconditioning apparatus100 will now be described. In basic operation, a plurality of damageddigital discs to be reconditioned are received from one or more rentalestablishments or other sources. An operator stacks the digital discs,with their protective coating side facing upward, and places the stackof discs into load cartridge 113. The operator then starts thereconditioning apparatus 100, which begins the reconditioning process asdescribed hereinbelow as sequenced and controlled by controller 105.

With the digital discs to be reconditioned stacked in load cartridge113, controller 105 activates motor 111 and, in response, bell crank 164rotates turntable 110 to the load position so that recess 112 ofturntable 110 is positioned directly beneath load cartridge 113. Thebottom digital disc drops from load cartridge 113 and is deposited intorecess 112 of turntable 110. It should be understood that only a singledigital disc is deposited into recess 112 of turntable 110, with theother digital discs remaining in load cartridge 113. Motor 111 thencauses bell crank 164 to rotate turntable 110 clockwise to the unloadposition so that the damaged digital disc in recess 112 of turntable 110is positioned beneath the first set of suction tools 130.

Controller 105 next actuates pneumatic cylinder 173 and, in response,shaft 124 is rotated so that the first set of suction tools 130 movedownwardly into contact with the protective coating of the digital discin recess 112 of turntable 110. Suction tools 130 then grasp the digitaldisc from recess 112 of turntable 110 using the suction therein. Next,pneumatic cylinder 173 causes reciprocal shaft 124 to rotate so thatsuction tools 130 move upwardly away from recess 112 of turntable 112until the digital disc is held in a generally vertical orientation.

With the digital disc held in a generally vertical orientation,controller 105 actuates pneumatic cylinder 174 and, in response, shaft124 is retracted horizontally until the digital disc is positionedadjacent turntable 120 of the first workstation. Next, controller 105actuates pneumatic cylinder 173 and, in response, shaft 124 is rotatedso that the first set of suction tools 130 move downwardly towardsturntable 120 so that the digital disc is held in a generally horizontalorientation above turntable 120. Controller 105 then terminates thesuction to suction tools 130 so that the digital disc is released anddeposited onto turntable 120.

Next, controller 105 again actuates pneumatic cylinder 173 and, inresponse, shaft 124 is rotated so that the first set of suction tools130 move upwardly away from turntable 120. Controller 104 then actuatespneumatic cylinder 174 and, in response, shaft 124 is retracted backhorizontally until the first set of suction tools 130 are returned totheir starting position above turntable 110. As such, the first set ofsuction tools 130 are in place to retrieve another digital disc fromrecess 112 of turntable 110.

With the digital disc deposited onto turntable 120 of the firstworkstation, controller 105 activates motor 133 so as to rotateturntable 120. Controller 105 also actuates pneumatic cylinder 143 and,in response, upper head 140 is lowered on guide rails 141, 142 untilworktools 144, 145, 146 contact the digital disc on turntable 120.Controller 105 then activates motor 147 so as to rotate worktools 144,145. The contact between worktools 144, 145 and the digital disc onturntable 120 operates to coarsely sand the protective coating of thedigital disc. The head of worktool 146 exerts sufficient force on thedigital disc so as to maintain the digital disc on turntable 120 duringthe course sanding operation.

Following the completion of the coarse sanding operation, controller 105actuates pneumatic cylinder 143 and, in response, upper head 140 israised on guide rails 141, 142 so as to disengage worktools 144, 145,146 from contact with the sanded digital disc on turntable 120.Controller 105 also deactivates motor 147 so as to cease rotation ofworktools 144, 145, and deactivates motor 133 so as to cease rotation ofturntables 120.

In another iteration of the sequence described hereinabove, the digitaldisc is transferred from the first workstation to the second workstationand, simultaneously, another digital disc is transferred from load area101 to the first workstation. It should be understood that eachsubsequent iteration adds an additional digital disc such that, afterfour iterations, apparatus 100 will be simultaneously course sanding adigital disc at the first workstation, fine sanding a digital disc atthe second workstation, rinsing and waxing a digital disc at the thirdworkstation, and polishing a digital disc at the fourth workstation. Ofcourse, after a digital disc is polished at the fourth workstation, itis transferred to receiving cartridge 163 of unload area 104. Thisprocess continues until all of the digital discs in load cartridge 113of load area 101 have been reconditioned and transferred to receivingcartridge 163 of unload area 104 for manual retrieval by the operator.

Second Exemplary Embodiment

Referring to FIG. 5, a reconditioning apparatus constructed inaccordance with a second exemplary embodiment of the present inventionis illustrated generally at 200. Apparatus 200 comprises a housing 202with six principal operating areas, namely, a load area generallyillustrated at 204, an unload area generally illustrated at 206, atransfer mechanism area generally illustrated at 208, a workstation areagenerally illustrated at 210, a controller area generally illustrated at212, and a cartridge area generally illustrated at 214. Each of theseoperating areas will be described in detail hereinbelow.

As can be seen in FIG. 5, housing 202 comprises a generally rectangularbase 216 and a tower 218 extending upwardly from the rear center portionof base 216. Base 216 and tower 218 each comprise exterior walls joinedto define a generally hollow interior portion. Electrical and fluidconnections between components of the various operating areas are routedthrough the hollow interior portion of base 216 and tower 218 (asdescribed in greater detail hereinbelow). The upper portion of tower 218includes a lid 220 that is hingedly attached along its lower rear edgeto tower 218. Thus, lid 220 may be lifted upwardly along its lower rearedge to allow access to the interior portion of tower 218 (i.e., whereworkstation area 210 is generally located).

Switches 222 located on the front wall 224 of base 216 allow an operatorto manually operate and reset the apparatus. A power switch (not shown)located on the rear of base 216 allows an operator to apply or removeelectrical power to apparatus 200. A controller (not shown) locatedwithin tower 218 is operable to properly sequence the various eventsoccurring during the reconditioning process. In particular, thecontroller provides electrical output signals to, and receiveselectrical input or feedback signals from, the various components oftransfer mechanism area 208, workstation area 210, controller area 212and cartridge area 214. The controller may be any type of programmablecontrol computer, single-board computer, programmable logic controller(PLC), or other type of device known in the art for performing aprogrammed sequence of events. A controller suitable for purposes ofthis embodiment is a single-board computer using two Atmel T89C51AC2microprocessors, with one microprocessor dedicated to controlling thecleaning cartridge of the apparatus. Of course, other off-the-shelf orcustom controllers may be used to implement the control function of thisembodiment of the present invention, as will be apparent to thoseskilled in the art.

Load Area

Referring still to FIG. 5, load area 204 is located adjacent the frontright edge of base 216 of housing 202. Load area 204 includes a loadstack 232 configured to hold a plurality of digital discs 234 forreconditioning. In the illustrated embodiment, load stack 232 comprisesa curved front wall 238 and a curved rear wall 240 attached to andextending upwardly from a bottom wall 242. Bottom wall 242 is affixed tobase 216 so as to secure load stack 232 in place on housing 202. Bottomwall 242 is shaped as a truncated disc with two opposed flat edges andtwo opposed arced edges. Front wall 238 and rear wall 240 extendupwardly from the opposed arced edges of bottom wall 242 and are spacedsuch that the distance therebetween is slightly greater than thecircumference of a digital disc. As such, digital discs 234 may beeasily stacked in load stack 232 with the protective coating facingupward. As will be described in greater detail hereinbelow, a gap 244defined between front wall 238 and rear wall 240 allows a load arm 268of a disc transfer mechanism 260 to access digital discs 234 unimpeded.

Unload Area

Referring still to FIG. 5, unload area 206 is located adjacent the frontleft edge of base 216 of housing 202. Unload area 206 includes an unloadstack 246 configured to hold a plurality of digital discs 248 that havebeen reconditioned within apparatus 200. As can be seen, theconfiguration of unload stack 246 is similar to that of load stack 232.Specifically, unload stack 246 comprises a curved front wall 252 and acurved rear wall 254 attached to and extending upwardly from a bottomwall 256. Bottom wall 256 is affixed to base 216 so as to secure unloadstack 246 in place on housing 202. Bottom wall 256 is shaped as atruncated disc with two opposed flat edges and two opposed arced edges.Front wall 252 and rear wall 254 extend upwardly from the opposed arcededges of bottom wall 256 and are spaced such that the distancetherebetween is slightly greater than the circumference of a digitaldisc. As such, digital discs 248 may be easily stacked in unload stack246 with the protective coating facing upward after each disc isreconditioned by apparatus 200. As will be described in greater detailhereinbelow, a gap 258 defined between front wall 252 and rear wall 254allows an unload arm 270 of a disc transfer mechanism 260 to depositdigital discs 248 into unload stack 246 unimpeded.

Transfer Mechanism Area

Referring still to FIG. 5, transfer mechanism area 208 is locatedadjacent the front center edge of base 216 of housing 202 between loadarea 204 and unload area 206. Transfer mechanism area 208 includes adisc transfer mechanism 260 operable to transfer digital discs betweenload area 204, workstation area 210, and unload area 206. In theillustrated embodiment, disc transfer mechanism 260 comprises agenerally cylindrical column 262 having a flattened, open side 264extending upwardly from base 216 of housing 202. Disc transfer mechanism260 includes a pick-up mechanism 266 that extends outwardly from openside 264 of column 262. Pick-up mechanism 266 includes a load arm 268and an unload arm 270 arranged in an “L”-shaped configuration at anapproximately right angle to each other. Load arm 268 and unload arm 270are formed integrally with each other, although these components couldalternatively be formed as separate parts that are affixed to each otherto form a rigid piece.

A threaded lead screw 278 extends upwardly through the length of column262 approximately along its center axis. Pick-up mechanism 266 includesa threaded aperture (not shown) configured to mate with the threads oflead screw 278 so that it may be threaded onto lead screw 278 withincolumn 262. With pick-up mechanism 266 threaded onto lead screw 278,lead screw 278 may be turned so as to raise or lower pick-up mechanism266 on lead screw 278.

A motor 274 is located at the base of column 262 within the interiorportion of base 216 and is operable to drive a gear train 276 so as toturn lead screw 268. Motor 274 is preferably a reversible,direct-current motor that may operate in either forward or reverse modeso as to drive lead screw 278 in either direction and, thus, allowpick-up mechanism 266 to be raised or lowered on lead screw 278. In thisexemplary embodiment, motor 274 is a Globe Motors model 415A158-3. Withmotor 274 coupled to lead screw 278 through gear train 276, thecontroller can raise or lower pick-up mechanism 266 by sending anappropriate electrical signal to motor 274. Preferably, a limit sensoris coupled to lead screw 278 so as to provide a signal to the controllerwhen pick-up mechanism 266 has reached the limits of its operable travelon lead screw 278.

Load arm 268 includes a load hand 280 located at its distal end and,similarly, unload arm 270 includes an unload hand 282 located at itsdistal end. Load hand 280 and unload hand 282 each include a graspingmechanism for grasping and holding a digital disc. Preferably, proximitysensors are located on the underside of load hand 280 and unload hand282 so as to provide an electrical signal to the controller when therespective hand is within a predetermined proximity to a digital disc.

In this embodiment, the grasping mechanism of load hand 280 and unloadhand 282 includes three fingers that extend downwardly therefrom. Two ofthe fingers are in a fixed position, and the third finger is movablelongitudinally with respect to load hand 280 or unload hand 282. Themovable finger may be electrically actuated between a retracted position(in which the spacing between the three fingers is such that thegrasping mechanism may be inserted into the center hole of a digitaldisc) and an extended position (in which the spacing between the threefingers is such that the grasping mechanism frictionally engages theunderside of the center hole of the digital disc to thereby grasp andhold the digital disc). Thus, the controller can move the moveablefinger between the retracted position and the extended position bysending an appropriate electrical signal to the moveable finger ofeither load hand 280 or unload hand 282.

As shown in FIGS. 6 and 8, disc transfer mechanism 260 is rotatablebetween a first position (shown in FIG. 6) in which load arm 268 extendsoutwardly toward load area 204 and unload arm 270 extends outwardlytoward workstation area 210, and a second position (shown in FIG. 8) inwhich load arm 268 extends outwardly toward workstation area 210 andunload arm 270 extends outwardly toward unload area 206. FIG. 7 depictsdisc transfer mechanism 260 in its transition from the first position tothe second position. A stepper motor (not shown) is located within theinterior portion of base 216 and is operable to rotate disc transfermechanism 260 between the first position and the second position. Thecontroller can thus rotate disc transfer mechanism 260 by sending anappropriate electrical signal to the stepper motor. Suitable load area204, unload area 206, and disc transfer mechanism 260 (including theload arm, unload arm, stepper motor, and grasping mechanisms) areavailable commercially as a unit as part number ADL-100, manufactured byPrimera Technologies. Of course, other disc loading, unloading, andtransferring mechanisms, components, or systems may be used withoutdeviating from the scope of the present invention, and will be apparentto those skilled in the art.

Workstation Area

Referring to FIGS. 5-7, workstation area 210 includes a disc tray 294for receiving a disc to be reconditioned. Disc tray 294 is movablebetween a closed position (shown in FIG. 5) and an open position (shownin FIGS. 6 and 7). In the closed position, disc tray 294 issubstantially enclosed within workstation area 210 of tower 218 with itsfront panel 296 flush with the front wall of tower 218. In the openposition, disc tray 294 is fully extended outwardly from tower 218. Adisc tray actuating mechanism (not shown) located within tower 218includes an electrically actuated motor that is mechanically coupled todisc tray 294. As such, the controller can move disc tray 294 betweenthe closed position and the open position by sending an appropriateelectrical signal to the motor. A suitable disc tray actuating motor inaccordance with the present invention is commercially available fromOriental Motors, model AXH5100KC-A. Other motors may of course be usedwithout deviating from the scope of the present invention.

Turning now to FIG. 9, disc tray 294 includes a rectangular body 298with a circular recess 300 and drain trough 302 formed therein. Recess300 and drain trough 302 slope slightly towards the rear of disc tray294, with a drain hole 304 located at the lowest point of drain trough302. Slots 306 a and 306 b extend along opposite sides of body 298 andare configured to engage with rails (not shown) mounted within tower218. As such, disc tray 294 may slide along the rails between the closedposition and the open position. A disc-shaped turntable 308 is mountedwithin recess 300 and is sized to receive and support a digital discbeing reconditioned. A centering hole 310 extends through the center ofturntable 308 and is positioned to align with the center hole of adigital disc. Preferably, a resilient rubber pad 312 covers the topsurface of turntable 308 so as to provide a cushioned support surfacefor the digital disc and prevent the digital disc from turning orslipping on turntable 308. Thus, a digital disc placed onto turntable308 is held in position by the frictional engagement of the disc withrubber pad 312 and by the extension of centering nib 310 through thecenter hole of the disc.

Turning now to FIG. 10, a shaft 314 extends downwardly from the centerof turntable 308 and is coupled to a turntable gear 316 located on theunderside of disc tray 294. Turntable gear 316 is operable to rotateshaft 314, which in turn rotates turntable 308 within recess 300. Withdisc tray 294 in its closed position within tower 218, turntable gear316 engages with a drive gear 318 attached to a drive motor 320 mountedwithin tower 218. When actuated, drive motor 320 rotates drive gear 318and turntable gear 316 to thereby rotate shaft 314 and turntable 308. Assuch, the controller can rotate turntable 308 by sending an appropriateelectrical signal to drive motor 320. A suitable drive motor 320 inaccordance with the present invention is a variable speed, DC motorhaving a voltage-to-speed input to allow the controller to command themotor to rotate at predetermined speeds. For example, a command signallevel of 0.1 volts direct current (VDC) from the controller may commandthe drive motor 320 to a rotational speed of 100 rpm, while a commandsignal level of 2.5 VDC from the controller may command the drive motorto a rotational speed of 1500 rpm.

Looking now to FIGS. 13 and 14, a worktool housing 324 is provided aboveturntable 308. Worktool housing 324 supports worktools 326, 328 a, 328 band nozzles 330 a, 330 b, 332, which are used to recondition a digitaldisc 322 on turntable 308. As best shown in FIGS. 11 and 12, worktool326 comprises a centering tool located in the center of worktool housing324, and worktools 328 a, 328 b comprise reconditioning tools located onopposite sides of centering tool 326. Also, nozzles 330 a, 330 bcomprise polish nozzles located on opposite sides of centering tool 326,and nozzle 332 comprises a rinse nozzle located forward of centeringtool 326.

Looking still to FIGS. 11 and 12, centering tool 326 comprises a plungershaft 334 that extends through a boss 336 of worktool housing 324. Onthe underside of worktool housing 324, plunger shaft 334 is coupled to aplanetary gear 338 and a centering disc 340. As best shown in FIG. 12,centering disc 340 includes a resilient rubber pad 342 that covers itslower surface so as to frictionally engage digital disc 322. A centeringnib or spindle 344 extends downwardly from centering disc 340 and isconfigured to fit within and engage the center hole of digital disc 322.

Referring to FIGS. 13 and 14, plunger shaft 334 is configured to fitwithin an electrically actuated solenoid housing (not shown) locatedabove worktool housing 324. The solenoid housing is electrically coupledto the controller so that the controller can actuate the solenoid toeither extend or retract plunger shaft 334 through boss 336. Thus, asshown in FIG. 13, plunger shaft 334 may be extended so that centeringdisc 340 is moved downwardly with respect to worktool housing 324 sothat centering spindle 344 fits within the center hole of digital disc322 and rubber pad 342 frictionally engages the center portion ofdigital disc 322. Conversely, as shown in FIG. 14, plunger shaft 334 maybe retracted so that centering disc 340 is moved upwardly with respectto worktool housing 324 so that centering disc 340 does not contactdigital disc 322.

Looking still to FIGS. 13 and 14, it can be seen that reconditioningtools 328 a and 328 b have a configuration that is similar to that ofcentering tool 326. Specifically, reconditioning tool 328 a comprises asolenoid plunger shaft 346 a that extends through a boss 348 a ofworktool housing 324. On the underside of worktool housing 324, plungershaft 346 a is coupled to a planetary gear 350 a and a reconditioningdisc 352 a. Similarly, reconditioning tool 328 b comprises a solenoidplunger shaft 346 b that extends through a boss 348 b of worktoolhousing 324. On the underside of worktool housing 324, plunger shaft 346b is coupled to a planetary gear 350 b and a reconditioning disc 352 b.As best shown in FIG. 12, reconditioning discs 352 a, 352 b each includean abrasive pad 354 a, 354 b that covers its lower surface forreconditioning digital disc 322 (preferably by removing a portion of theprotective coating of digital disc 322 without removal of the dataunderlying the protective coating).

Looking again to FIGS. 13 and 14, plunger shafts 346 a, 346 b areconfigured to fit within electrically actuated solenoid housings (notshown) located above worktool housing 324. The solenoid housings areelectrically coupled to the controller so that the controller canactuate the solenoids to either extend or retract plunger shafts 346 a,346 b through bosses 348 a and 348 b, respectively. Thus, as shown inFIG. 13, plunger shafts 346 a, 346 b may be extended so thatreconditioning discs 352 a, 352 b are moved downwardly with respect toworktool housing 324 so that abrasive pads 354 a, 354 b frictionallyengage digital disc 322. Conversely, as shown in FIG. 14, plunger shafts346 a, 346 b may be retracted so that reconditioning discs 352 a, 352 bare moved upwardly with respect to worktool housing 324 so that abrasivepads 354 a, 354 b do not contact digital disc 322.

Various types of electrically actuated solenoid housings and plungershafts known in the art may be employed to achieve the objects of thepresent invention. It should be noted that while each of the threeworktools is separately operable, it is desirable that the tworeconditioning tools be operated in unison such that either both of theplunger shafts are extended with the associated reconditioning worktoolscontacting digital disc 322 (as shown in FIG. 13) or both of the plungershafts are retracted with the associated reconditioning worktools beingdrawn upwardly away from digital disc 322 (as shown in FIG. 14). As willbe described in greater detail hereinbelow, the controller is preferablyoperable to first extend centering tool 326 to contact and securedigital disc 322, then to extend reconditioning worktools 328 a, 328 bso that the reconditioning pads contact the surface of the digital disc.

During the reconditioning of digital disc 322, with worktool housing 324in place above digital disc 322, centering tool 326 is lowered tocontact the center portion of digital disc 322. Turntable 308 is rotatedvia drive motor 320 to approximately 1500 revolutions per minute so thatdigital disc 322 is likewise rotating at the same rate. Reconditioningworktools 328 a, 328 b are then lowered so as to contact digital disc322 on turntable 308 (as shown in FIG. 13). With worktools 326, 328 a,328 b contacting digital disc 322, centering disc 340 is frictionallyengaged against the center portion of digital disc 322 such thatcentering tool 326, and its associated planetary gear 338, rotate at thesame rate as digital disc 322. Planetary gear 338 of centering tool 326engages with planetary gears 350 a, 350 b of reconditioning tools 328 a,328 b. As such, the rotation of planetary gear 338 causes the rotationof planetary gears 350 a, 350 b, which in turn causes the rotation ofreconditioning discs 352 a, 352 b and their associated abrasive pads 354a, 354 b. Thus, with digital disc 322 rotating on turntable 308,abrasive pads 354 a, 354 b also rotate so as to recondition the surfaceof digital disc 322. In the embodiment shown, the planetary gears 350 a,350 b of reconditioning tools 328 a, 328 b are the same size as theplanetary gear 338 of centering tool 326. Thus, reconditioning tools 328a, 328 b rotate at the same speed as centering tool 326, which, asdescribed above, rotates at the same speed as digital disc 322 rotates.As will be apparent to one skilled in the art, gears having varioussizes and tooth arrangements may equally be used to allow thereconditioning tools to rotate at various rates with respect to therotational speed of centering tool 326, or to allow the reconditioningtools to each rotate at a different rate. Similarly, while the gearingarrangement in the embodiment shown is such that reconditioning tools328 a and 328 b rotate in opposite directions, other gearingarrangements or gear trains may be used to permit the reconditioningtools to rotate in the same direction.

Referring to FIGS. 11-14, worktool housing 324 also supports polishnozzles 330 a, 330 b and rinse nozzle 332. The inlets of polish nozzles330 a, 330 b are located on the top side of worktool housing 324 and areconnected to tubing routed to a polish pump (not shown) located in tower218. Similarly, the inlet of rinse nozzle 332 is located on the top sideof worktool housing 324 and is connected to tubing routed to a rinsepump (not shown) located in tower 218. The outlets of polish nozzles 330a, 330 b and rinse nozzle 332 are located on the underside of worktoolhousing 324 so that the polish and rinse solutions applied through thenozzles will be deposited onto digital disc 322. The pumps used todisperse the polish is preferably a peristaltic pump such as a modelWP-1000 manufactured by Welco. The rinse pump is preferably a Sullivanmodel S752. Of course, other types of pumps may be used without varyingfrom the present invention.

Controller Area

Referring again to FIG. 5, controller area 212 includes a control panel226 that extends along the front wall of lid 220. In the illustratedembodiment, five pushbutton switches 228 are arranged in a horizontalrow along the lower edge of control panel 226, and three liquid crystaldisplays (LCDs) 230 are arranged in a horizontal row along the upperedge of control panel 226. Labels beneath each of pushbutton switches228 identify the function (“start”, “stop”, “eject”, “cycle select”, and“lid release”) associated with the particular switch that will beperformed by the controller upon detecting that the switch has beenpressed. Pushbutton switches 228 are electrically coupled to thecontroller such that the controller can detect when a particular switchis pressed and perform a particular function in response. For example,if the controller detects the “Start” switch has been depressed, thecontroller will initiate the selected reconditioning process asdescribed in more detail herein below. Of course, the controller maycondition the initiation of the cycle upon other inputs, such as lid 220being latched closed, before starting the requested cycle.

LCDs 230 are also in electrical communication with the controller toallow alpha, numeric and graphical information to be conveyed to theoperator. Information such as operating instructions, feedback, andstatus information can be sent from the controller to LCDSs 230 fordisplay. For example, if lid 220 is not properly latched in position,the controller displays a “Lid Ajar” message on the LCD display.Similarly, the controller can prompt the user via LCDs 230 to “PressStart” to begin operation of the apparatus, or can display a percentageof cartridge life remaining status (e.g., “74%”). Of course, other typesof switches and displays known in the art may be used in accordance withthe present invention.

Cartridge Area

Referring to FIG. 5, cartridge area 214 is located generally at theright rear corner of base 216 at the junction with tower 218. Cartridgearea 214 includes a top wall 284, a bottom wall 286, and side walls 288a, 288 b, which together define a cartridge bay 290 for receiving andholding a cartridge 292 therein. Cartridge 292 is a generallycube-shaped cartridge that contains a polish solution reservoir forholding polish solution and a rinse solution reservoir for holding rinsesolution. While various types of polish and rinse solutions known in theart may be used, the polish solution is preferably an aluminum oxidepolish. Most preferably, the polish solution is an aluminum oxidesuspension solution, and the rinse solution is deionized water.

Four female receptacle fittings are located on the inner wall ofcartridge 292—two of which connect with the polish solution reservoirand two of which connect with the rinse solution reservoir. The tworeceptacle fittings that connect with the polish solution reservoirinclude an outlet port through which polish solution is dispersed toworkstation area 210 and an inlet port through which used polish andrinse solution is returned to the polish solution reservoir. The tworeceptacle fittings that connect with the rinse solution reservoirinclude an outlet port through which rinse solution is dispersed toworkstation area 210 and a breather port through which ambient airenters the reservoir to replace the dispersed rinse solution. The fourreceptacle fittings of cartridge 292 mate with four corresponding maleO-ring sealed fittings located on the inner wall of cartridge bay 290 soas to allow fluid and air to pass into and out of cartridge 292 throughthe receptacle fittings.

Various tubing connects cartridge 292 to the interior of base 216 andtower 218. Specifically, tubing connects the outlet port of the polishsolution reservoir to a polish pump (not shown) mounted in tower 218,and tubing connects the outlet port of the rinse solution reservoir to arinse pump (not shown) mounted in tower 218. In addition, tubingconnects the inlet port of the polish solution reservoir to drain hole304 in disc tray 294 of workstation area 210 so as to collect usedpolish and rinse solution in the polish solution reservoir. The breatherport of the rinse solution reservoir is open to the atmosphere, thusallowing ambient air to enter the rinse solution reservoir so as toreplace the dispersed rinse solution.

The polish pump and rinse pump are electrically actuated and, thus, maybe independently actuated by the controller. The controller actuates thepolish pump so as to move polish solution from the polish solutionreservoir through tubing to workstation area 210 (where polish nozzles330 a, 330 b disperse the polish solution over the digital disc beingreconditioned). Similarly, the controller actuates the rinse pump so asto move rinse solution from the rinse solution reservoir through tubingto workstation area 210 (where rinse nozzle 332 disperses the rinsesolution over the digital disc being reconditioned).

Preferably, cartridge 292 further comprises a smart chip microcontrolleroperable to monitor and record the number of repair cycles performed bycartridge 292. Electrical contact points on cartridge 292 engage withelectrical contact points on the inner wall of cartridge bay 290 so asto allow communication between the smart chip microcontroller and thecontroller. Based on the usage information received from the smart chipmicrocontroller, the controller provides a “percent used” or “percentremaining” indicator to the operator through one of LCDs 230 and, if theusage exceeds a predetermined limit, prohibits operation of apparatus200 with the spent cartridge 292.

In this embodiment, three different types of cartridges may be used withapparatus 200, namely, a repair cartridge, a buffing cartridge or aself-cleaning cartridge. Upon detection of a repair cartridge, thecontroller will command apparatus 200 to perform either light, medium,or heavy reconditioning based on input from the operator. A lightreconditioning cycle is used for discs having a few, or light scratches,a medium reconditioning cycle is used for discs having more than a few,or medium scratches, and a heavy reconditioning cycle is used for discshaving several, or heavy scratches. Upon detection of a buffingcartridge, the controller will command apparatus 200 to perform a lightbuffing operation. Upon detection of a self-cleaning cartridge, thecontroller will command apparatus 200 to perform a self-cleaningoperation. Preferably, each type of cartridge is identified byinformation programmed into the smart chip microcontroller of thecartridge.

Operation

As will be described in greater detail hereinbelow, the reconditioningapparatus according to this second embodiment of the present inventionis operable to: (1) move disc transfer mechanism 260 to the firstposition (shown in FIG. 6); (2) lower pick-up mechanism 266 until loadhand 280 is in proximity to a digital disc 234 on load stack 232; (3)actuate the grasping mechanism of load hand 280 so as to grasp and holdthe top digital disc on load stack 232; (4) raise pick-up mechanism 266(and the grasped digital disc) out of load stack 232; (5) rotate disctransfer mechanism 260 (and the grasped digital disc) to the secondposition (shown in FIG. 7); and (6) actuate the grasping mechanism ofload hand 280 to release the digital disc so as to deposit the digitaldisc in workstation area 210.

With reference to FIGS. 5-14, the operation of reconditioning apparatus200 will now be described in greater detail. In basic operation, anoperator securely inserts cartridge 292 into cartridge bay 290 so thatthe four receptacle fittings of cartridge 292 engage with the fourO-ring sealed fittings on the inner wall of cartridge bay 290. Withcartridge 292 firmly inserted, the electrical contact points oncartridge 292 mate with the electrical contacts on the inner wall ofcartridge bay 290, thus allowing communication between the smart chipmicrocontroller on cartridge 292 and the controller. The operator thenpowers on the machine using the power switch on the rear of base 216.

Upon power up, the controller communicates with the smart chipmicrocontroller on cartridge 292 to determine whether the cartridge is astandard repair cartridge, a buffing cartridge, or a self-cleaningcartridge. Depending on the type of cartridge present, the controllermay provide appropriate prompts to the operator through LCDs 230 toselect (using the “cycle select” pushbutton switch), for example, eitherlight, medium, or heavy reconditioning.

It should be understood that the initialization sequence performed bythe controller may vary without deviating from the scope of the presentinvention. For example, the controller may query the smart chipmicrocontroller on cartridge 292 prior to commanding movement of disctransfer mechanism 260. Likewise, the controller may prompt the operatorvia LCDs 230 to confirm that the operating area is clear, and thatoperator wants to allow movement of disc transfer mechanism 260. Othervariations in the initialization sequence will be apparent to thoseskilled in the art and are within the scope of the present invention.

Where the controller has detected a repair cartridge in cartridge bay290, the operator loads a stack of digital discs to be reconditionedinto load stack 232 with the protective coating facing upward. Thecontroller then prompts the operator via LCDs 230 to select a “light”,“medium”, or “heavy” reconditioning cycle using the “cycle select”pushbutton switch 228. With the desired cycle selected, the controllerprompts the operator via LCDs 230 to press the “start” pushbutton switch228.

Upon detecting that the “start” pushbutton switch 228 has been pressed,the controller sends a command signal to the stepper motor in base 216to ensure that disc transfer mechanism 260 is rotated to its firstposition (as shown in FIG. 6), if it is not already in that positionfrom the power-up cycle. The controller then sends a command signal tomotor 274 so as to turn lead screw 278 and thereby lower pick-upmechanism 266 and load hand 280 towards the top digital disc on loadstack 232. When the feedback signal from the proximity sensor indicatesthat load hand 280 is in close proximity to the top digital disc, thecontroller stops the command signal to motor 274, at which point thefingers of the grasping mechanism on load hand 280 extend through thecenter hole of the top digital disc. Next, the controller commands theoperable finger of the grasping mechanism on load hand 280 to extend sothat the grasping mechanism grasps and holds the top digital disc.

With the top digital disc now securely held by the grasping mechanism ofload hand 280, the controller sends a command signal to motor 274 so asto rotate lead screw 278 and raise pick-up mechanism 266 to it uppermostraised position. When the signal from limit sensor on lead screw 278indicates that pick-up mechanism 266 has reached its uppermost raisedposition, the controller stops the command signal to motor 274 wherebythe grasped digital disc is held in position above load stack 232,awaiting its movement into workstation area 210 for reconditioning asdescribed below.

With load hand 280 located above load stack 232 grasping a disc as justdescribed, unload hand 282 is similarly located in workstation area 210,ready to retrieve a reconditioned digital disc from turntable 308 ondisc tray 294. With load hand 280 thus positioned, the controller nextsends a command signal to the motor of disc tray 294 so as to move disctray 294 to its open position to allow retrieval of a reconditioned discfrom the tray. Of course, as will be apparent, during this firstiteration of the reconditioning process there will be no reconditioneddisc to retrieve from turntable 308. However, upon subsequentiterations, a reconditioned disc will be present on turntable 308, readyfor retrieval. To retrieve the reconditioned disc, the controller sendsa command signal to motor 274 so as to turn lead screw 278 and lowerpick-up mechanism 266 and unload hand 282 towards turntable 308 of disctray 294. While pick-up mechanism 266 is lowering, the controllermonitors the feedback signal from the proximity sensor located on unloadhand 282. As pick-up mechanism 266 lowers, the fingers of the graspingmechanism on unload hand 282 lower into the center hole of thereconditioned digital disc on turntable 308. When the feedback signalfrom the proximity sensor indicates that unload hand 282 is in closeproximity to the reconditioned disc on turntable 308, the controllerstops the command signal to motor 274, holding pick-up mechanism 266 inposition, with unload hand 282 held in place directly above thereconditioned disc on turntable 308. Next, the controller commands theoperable finger of the grasping mechanism in unload hand 282 to extendso that the fingers of the grasping mechanism frictionally engage andhold the edges of the center hole of the reconditioned digital disc.

With the reconditioned disc now securely held by the grasping mechanismof unload hand 282, and the top digital disc from load stack 236 stillsecurely held by the grasping mechanism of load hand 280, the controllercommands motor 274 to rotate lead screw 278 to raise pick-up mechanism266 to it uppermost raised position. When the signal from limit sensoron lead screw 278 indicates that the pick-up mechanism 266 is at itsuppermost raised position, the controller stops the command signal tomotor 274. The controller then sends a command signal to the steppermotor in base 216 to rotate disc transfer mechanism 260 to the secondposition as shown in FIG. 8, with the grasped reconditioned disc heldabove unload stack 246 and the grasped digital disc from load stack 232held above turntable 308 on extended disc tray 294.

Looking to FIG. 8, with disc transfer mechanism 260 in the secondposition, the controller commands the operable finger of the graspingmechanism of unload hand 282 to retract, whereby the reconditioneddigital disc is released and is deposited into unload stack 246.Likewise, the controller then commands the operable finger of thegrasping mechanism of load hand 280 to retract, so that the digital disctaken from the top of load stack 236 is released and is deposited ontoturntable 308. The controller next commands the motor of the disc trayactuating mechanism in tower 218 to retract disc tray 294 intoworkstation area 210, where the disc will be reconditioned as describedhereinbelow.

This load/unload sequence of transferring digital discs to bereconditioned from load stack 236 to turntable 308, and transferringreconditioned discs from turntable 308 to unload stack 246 is repeateduntil there are no more discs remaining to be reconditioned, asindicated by the limit sensor on lead screw 278 signaling the controllerthat pick-up mechanism 266 has reached its lower limit.

As described hereinabove, after a disc to be reconditioned has beendeposited on turntable 308, the controller commands disc tray 294 toretract into workstation area 210. As shown in FIGS. 9-14, once disctray 294 is retracted into the workstation area, turntable 308 ispositioned beneath worktool housing 324, supporting digital disc 322 forreconditioning by the worktools. Also, when disc tray 294 is retracted,as shown in FIG. 10, turntable gear 316 engages with drive gear 318.When disc tray 294 is retracted and digital disc 322 is positionedbeneath the worktool housing 324, the controller provides actuationsignals to extend the centering tools' plunger shaft 334 such that thecentering disc pad frictionally engages the center portion of digitaldisc 322.

With digital disc 322 thus secured, the controller next commands thepolish pump in tower 218 to begin pumping polish solution from cartridge292, through tubing, to polish nozzles 330 in worktool housing 324. Thepolish solution is sprayed from polish nozzles 330 onto the protectivecoating on the surface of digital disc 322.

After a delay of approximately five seconds, the controller commandsreconditioning tools 328 a, 328 b to extend so that the reconditioningtool plunger shafts 346 a, 346 b are extended such that the abrasivepads 354 a, 354 b of the reconditioning discs 352 a, 352 b engage theouter, protective layer portion of digital disc 322.

The controller then commands drive motor 320, preferably via a 2.5 VDCcommand signal to the motor's voltage-to-speed input as discussed above,to a rotational speed preferably in the range of approximately 1000 to2500 revolutions per minute (rpm), most preferably approximately 1500rpm, thus spinning turntable 308, digital disc 322, and frictionallyengaged centering disc 340 to that speed. As described previously, withcentering disc 340 rotating due to its frictional engagement withdigital disc 322, planetary gear 338 also rotates, which in turn rotatesplanetary gears 350 a, 350 b on each of reconditioning tool 328 a, 328b. The rotating planetary gears 350 a, 350 b each rotate theirrespective plunger shafts 346 a, 346 b, in turn rotating reconditioningdiscs 352 a, 352 b and their associated abrasive pads 354 a, 354 b.Thus, with digital disc 322 rotating on turntable 308 beneath abrasivepads 354 a, 354 b, as the abrasive pads simultaneously rotate on theirplunger shafts, polishing the surface of disc 322, and with polishingsolution being sprayed continuously onto the protective surface ofdigital disc 322 through polish nozzles 330, the protective surface ofdigital disc 322 is polished and reconditioned so that scratches andabrasions are removed from the protective surface.

As the reconditioning process continues, excess polish solution dripsover the outer edge of digital disc 322 into recess 300 on disc traybody 298. In addition, polish solution thrown from the spinning disc isdiverted by a shield (not shown) within workstation area 210 back ontodisc 322 and into recess 300. Used polish solution drains into draintrough 302 and to drain hole 304, where tubing routes the used polishsolution back to the polish reservoir on cartridge 292, where it isremixed with the polish solution and reused.

Depending on the reconditioning cycle chosen by the operator, thereconditioning process continues for a period of approximately two andone-half minutes (light), approximately five minutes (medium), orapproximately eight minutes (heavy), respectively. After the appropriatereconditioning time has elapsed, the controller commands the polish pumpto stop pumping polish solution to the digital disc, and commands thereconditioning tool plunger shafts 346 a, 346 b to perform aretract/extend/retract cycle three times in approximately five secondsso that the abrasive pads 354 a, 354 b of the reconditioning discs 352a, 352 b are repeatedly raised from and lowered against the surface ofdigital disc 322 to shake any remaining polish off of the abrasive pads.The reconditioning tool plunger shafts are then again extended so thatthe clean abrasive pads contact the surface of digital disc 322.

The controller then commands drive motor 320, preferably via a 0.1 VDCcommand signal to the motor's voltage-to-speed input as discussed above,to a rotational speed preferably in the range of approximately 10 to 200revolutions per minute (rpm), most preferably approximately 100 rpm, andcommands the rinse pump in tower 218 to begin pumping rinse solutionfrom cartridge 292, through tubing, to rinse nozzle 332 in worktoolhousing 324. The rinse solution is sprayed from rinse nozzles 332 ontothe protective coating on the surface of digital disc 322. Rinsesolution is applied for approximately one-half second, after which timethe controller commands the rinse pump to stop pumping rinse solution.

The controller continues to rotate turntable 308 at approximately 100rpm for approximately seven seconds, then commands the reconditioningtool 328 a, 328 b solenoid housings to retract the reconditioningworktools' plunger shafts 346 a, 346 b so that the reconditioningworktools are drawn up into worktool housing 324, away from the surfaceof digital disc 322. The controller continues to command drive motor 320to rotate turntable 308 at 1500 revolutions per second for a period oftime, preferably approximately eight seconds, to spin any remainingpolish or rinse solution off of digital disc 322. The controller thencommands centering tool 326 solenoid housing to retract the centeringtools' solenoid plunger shafts 334 such that the centering tool is drawnup into worktool housing 324, away from the surface of digital disc 322,and commands drive motor 320 to stop. Used rinse solution from the rinsecycle is captured through recess 300 and drain trough 302 and routedback to the polish reservoir where it is mixed with the polish solution.As described hereinabove, the smart chip microcontroller on cartridge292 maintains a record of use time for the cartridge so that therecycled polish solution never becomes too diluted or too dirty forreuse.

With the reconditioning process complete, the controller commands disctray 294 to extend from workstation area 210 so that the reconditioneddisc may be unloaded as previously described. Thisload/unload/reconditioning sequence continues until there are no morediscs remaining to be reconditioned, as indicated by the limit sensor onlead screw 278 signaling the controller that pick-up mechanism 266 hasreached its lower limit.

With all of the discs from load stack 236 reconditioned and depositedinto unload stack 250, the operator can remove the reconditioned discsfrom unload stack 246, and power off the apparatus.

Variations on this automatic reconditioning process are anticipated bythe present invention. For example, while the sequence describedinvolves an operator selecting a reconditioning cycle (light, medium, orheavy) for the entire load stack of discs, it is also possible for theoperator to arrange the load stack of discs with discs requiring varyingdegrees of reconditioning, and programming the controller via thepushbutton switches to perform the required reconditioning cycle onthose particular discs. Thus, an operator may arrange a load stackcomprising ten discs requiring a light cycle, twenty discs requiring amedium cycle, and eleven discs requiring a heavy cycle. Stacking thediscs in the appropriate order and programming the controller to performthe appropriate cycles in that same order allows the reconditioningprocess to take place unattended once the operator provides theappropriate programming. Other variations on the specific sequence ofsteps described herein will be apparent to those skilled in the art, andare within the scope of the present invention.

When the controller detects a polish cartridge present in cartridge bay290, the controller will only perform a light polishing or buffreconditioning cycle of approximately thirty seconds. The operation ofthe load/unload/reconditioning cycles are the same as describedhereinabove in the repair cartridge description, except that theoperator will not be prompted for a desired reconditioning level, andthe controller will only recondition each disc for thirty seconds.

When the controller detects a self-cleaning cartridge present incartridge bay 290, the controller will not recondition any discs, butwill only perform an apparatus self cleaning. In the self-cleaningcycle, after the operator presses “start”, the controller commands thepolish pump in tower 218 to begin pumping cleaning solution fromcartridge 292, through tubing, to polish nozzles 330 in work housing324. The cleaning solution is sprayed from polish nozzles 330 intoworkstation area 210. The used cleaning solution is collected in recess300 on disc tray body 298. Used cleaning solution drains into draintrough 302 and to drain hole 304, where tubing routes the used solutionback to the cleaning solution reservoir on cartridge 292. After apredetermined amount of time, the controller stops polish pump, and theoperator is prompted to remove the self-cleaning cartridge.

While the present invention has been described and illustratedhereinabove with reference to several exemplary embodiments, it shouldbe understood that various modifications could be made to theseembodiments without departing from the scope of the invention.Therefore, the invention is not to be limited to the specificembodiments described and illustrated hereinabove, except insofar assuch limitations are included in the following claims.

1. An apparatus for automatically reconditioning a plurality of digitaldiscs, each of said digital discs comprising data underlying aprotective coating, said apparatus comprising: a. a load area configuredto hold said plurality of digital discs; b. at least one workstation forreconditioning each of said digital discs, said workstation comprisingat least one worktool operable to remove a portion of said protectivecoating of each of said digital discs without removal of said dataunderlying said protective coating; c. an unload area configured to holdsaid plurality of digital discs after reconditioning; and d. a disctransfer mechanism operable to transfer each of said digital discs fromsaid load area to said workstation, said disc transfer mechanism alsooperable to transfer each of said digital discs from said workstation tosaid unload area.
 2. The apparatus of claim 1, wherein said plurality ofdigital discs are reconditioned without manual manipulation of saiddigital discs to thereby provide automated reconditioning of saiddigital discs within said apparatus.
 3. The apparatus of claim 1,further comprising a controller operable to control said workstation andsaid disc transfer mechanism.
 4. The apparatus of claim 1, wherein saidload area comprises a load cartridge.
 5. The apparatus of claim 1,wherein said load area comprises a load stack.
 6. The apparatus of claim1, wherein said disc transfer mechanism comprises at least one suctiontool operable to grasp each of said digital discs from said load areaand deposit each of said digital discs at said workstation.
 7. Theapparatus of claim 6, wherein said disc transfer mechanism furthercomprises a second suction tool operable to grasp each of said digitaldiscs from said workstation and deposit each of said digital discs atsaid unload area.
 8. The apparatus of claim 1, wherein said disctransfer mechanism comprises a rotatable pick-up mechanism with at leastone arm operable to grasp each of said digital discs from said load areaand deposit each of said digital discs at said workstation.
 9. Theapparatus of claim 8, wherein said rotatable pick-up mechanism furthercomprises a second arm operable to grasp each of said digital discs fromsaid workstation and deposit each of said digital discs at said unloadarea.
 10. The apparatus of claim 1, wherein said workstation furthercomprises a rotatable turntable configured to support each of saiddigital discs.
 11. The apparatus of claim 1, wherein said unload areacomprises an unload cartridge.
 12. The apparatus of claim 1, whereinsaid unload area comprises an unload stack.